The side windows of Efaki made out of Plexiglas have had lost their
transparency due to probably polymerization of age and sun. In a few spots they
were broken too. So in 2003 was time to renew them since I didn't want any leaks in
the cabin now that the new upholstery was about to be installed.

What I did was take
the old windows out, cover temporarily with plastic vinyl attached with tape on
the coach roof until the new ones are ready to be placed again in their
position. Each of the windows has more that 50 screws to keep it in place.

Then since
that there are not so long Plexiglas lengths anymore imported (each window more
that 3 meters long), I had to measure the exact place where the windows will be split
to form a two piece window per side. Although the new windows will not
be identical to the originals, that fact suits me in the logic that possible
breaks of Plexiglas or leaks will be easier to deal with.

This is part
of the left window and to be more specific the bow part. The point of the mark
(line of tape) shows where the window will be split. This point is at 1,8
meter from the bow start of the window and includes the windows of the fore
cabin and that of the heads.

Update April 1st 2003:

Well finally on Saturday March 30th
weather permitting I installed the new windows. As I had given only one window
to be used as a pattern to cut the new ones from Plexiglas (in UK I think they
call it Perspex) I had to drill the holes in each window separately
(unfortunately the holes were not symmetrical so as to drill them
simultaneously) for the screws that bolt the windows to the boat.

The trick I
used was very simple so as to have exact and accurate holes in each window since
the slightest difference would not permit a nice "fit" on board. I
placed each new window on the old one and taped it so as to be as exact as
possible. Then I placed them on a long plank so as to have a flat surface
to drill without the danger of breaking the new Plexiglas.

In the left
picture you may see the long plank that was used to place the sandwich of the
old and new Plexiglas for drilling. In the right picture you may notice the tape
that was used to attach the old with the new Plexiglas.

After drilling the two
"stern" windows (left and right or to be exact port and starboard)
these were placed on their positions before drilling the "bow" windows
since now that I sliced each side window to two pieces I needed to take new
measurements so as to be sure for the placement of these. Here again the old
motto measure twice and cut once was very useful.

Before placing the
windows on the coach roof I had to prepare it. I used my electric scraper to
remove the old silicon and the sander to clean up entirely. Then after an
initial test to see that every hole was accurate, new silicon was applied and
the window was positioned in place. Then the screws were placed in each hole
with a drop of silicon to ensure a good seal.

After
the placement of the "stern" windows, exact measurements were taken to
facilitate the placement of the "bow" windows. As it finally proved
only in the starboard side window the bow window was 1mm longer than it should
and that was filled out. Then the holes were made using the same trick as for
the stern parts, and then I finally installed the bow parts too.

Unfortunately
my camera run out of batteries so pictures of the finished job will appear the
next time I go to the boat. The final result is very nice, it's not easy at all
to spot that there are two parts each side instead of a long one, and there is
clarity now long so as to observe when you are in the cabin what is going on
outside. This job took me about six hours to be accomplished. Next project:
placement of the new upholstery after ensuring waterproof ness.

View from inside.

Update April 3rd 2003:

Finally I went yesterday to the
boat and took some pictures of the finished job.

It is amazing the difference in the
colors of the two photographs because of the light. Both above pictures were
taken the same time.

In
these pictures I wanted to show that a small final task is to complete the job.
Since now each side the window is not in one piece but in two the screws that
are in the up and down side of the Plexiglas do not hold the windows firmly
attached together in the point of the joint. So I have to drill at least one or
two new holes to each part of the Plexiglas at the "center" of the
joining spot to keep it well bolted on the coach roof. This will be done one of
these days. And end of job.

This page was last updated: April 3rd 2003.

Update March 29th 2005:

Finally when I changed the windows of Efaki
in the Spring of 2003 I did a serious error. The Plexiglas used was very thick
and as a result not only I have had leaks but lately because of the flexing due
to sun heat at least one of the windows has been broken to a few places. So I
have to renew once more the windows, this time with a heavier Plexiglas. I'll
let you know when and how I'm going to do so.

Update Spring 2006:

May 1st 2006:

I have removed the side windows in order to renew them. I order to do so, I
had to remove also the upholstery which it was a good thing to do since I
discovered that below there was a lot of humidity because of the leaking
windows. The next few days I'll have the new windows made and report back for
costs and procedures of installment.

May 10th 2006:

The new ones are of 8mm plexiglas
and the cost to acquire them was 210 Euros. I had to sand the external sides to
the corners in order to make them smooth so as to avoid a potential accident of
somebody cutting his leg while touching the rough corners. After that I had to
drill the four pieces (I again have split each side's window to two pieces)
which resulted in a broken piece that was replaced at a cost of 35 Euros.
Yesterday I spend two hours cleaning the cabin sides of old adhesives and dirt
before installment of the left side's two pieces. The fact that I used white
adhesive didn't make them look nice so I removed them and cleaned them to
install them today with black adhesive. This is Sikaflex 295 especially made for
this purpose and it comes with a primer for the plexiglas (24 Euros for a tube
and a little bottle of primer). This is also a detail that I was not aware off
as I used the primer for the cabin sides. So today armed with new knowledge and
materials I'll try again.

This is one of the new plexiglas windows after the sanding of the corners
which prevent them acting like knives tearing our skin if touched. Then I
drilled them by taping each pair of new and old one together so as to have an
exact match on the holes of the cabin side which last night didn't provide any
difficulties. New longer stainless steel screws (20mm) were bought for this
purpose.

May 17th 2006:

The installation of the side windows is now complete and the relevant tests
with the hose proved that there are no water leaks!